Adaptive rfid inventory system

ABSTRACT

An adaptive inventory management system for use in a materials handling facility storing a plurality of items that are each associated with a Radio Frequency Identification (RFID) tag. The management system including a global inventory database subsystem and a RFID interrogator subsystem comprising a plurality of RFID interrogators that are each configured to read the unique identifier of the RFID tag associated with each of the plurality of items that are within a defined boundary of at least one scan zone generated by the respective RFID interrogator and to communicate the unique identifier of the each scanned RFID tag identified within each scan zone of the respective RFID interrogator to the global inventory database subsystem. The management system being selectively configured to effect user desired levels of fidelity and/or resolution with respect to the generated unique identifier of the each scanned RFID tag within a defined space of the materials handling facility.

CROSS-REFERENCE TO RELATED APPLICATIONS

This application claims benefit of priority from U.S. ProvisionalApplication No. 63/149,016, titled AN ADAPTIVE WAREHOUSE RFID INVENTORYSYSTEM, which was filed Feb. 12, 2021; U.S. Provisional Application No.63/219,613, titled AN ADAPTIVE WAREHOUSE RFID INVENTORY SYSTEM, whichwas filed Jul. 8, 2021; and U.S. application Ser. No. 17/484,885, titledADAPTIVE RFID INVENTORY SYSTEM, which was filed Sep. 24, 2021, all ofthe noted applications being hereby incorporated by reference. and.

TECHNICAL FIELD

The present disclosure relates generally to systems, apparatus andmethods in the field of tracking items (e.g., an object, a package, apiece of equipment) and, more particularly, to various aspects involvingsystems, apparatus and methods for improved asset identification andlocation services using an adaptive, warehouse racking radio-frequencyidentification inventory system.

BACKGROUND

Supply chain management is utilized to manage the storage and movementof goods, including raw materials, work-in-process, and finished goods,from the point of origin to points of purchase or consumption. Reasonsto accurately account for articles in a warehouse include trackingshipments from a bulk vendor, reduction of inventory for just-in-timemanufacturing operations, reduction of shrinkage due to breakage andpilfering, managing claims against a manufacturer, and validating salesand other dispositions of articles. With continued growth and emphasison efficiency of enterprises such as retail and warehousing operations,for both online commerce and physical brick-and-mortar stores, it isincreasingly important to account for and track the actual inventory ateach enterprise location in real time. The ability to identify an itemand locate its whereabouts is a core competency for companies that usevarious forms of warehousing for product or part inventory. Companiestypically invest in creating and maintaining a highly organized networkfor tracking its items, e.g., packages, objects, and the like, to lowercosts and enhance operational efficiencies.

Conventionally, this identification and tracking function may beprovided by a variety of known mechanisms and systems. Machine-readablebarcodes are one way organizations keep track of items. In one example,in order to keep track of inventory, the operator typically scans orotherwise captures an image of the bar code on each item so that aback-end part of the operator's operation can keep track of what iscoming in and leaving their warehouse. In addition, when an item isremoved from the premises, the bar code for that item is scanned orcaptured to track inventory levels. Bar codes, however, have thedisadvantage that personnel must manually scan each bar code on eachitem in order to effectively track the items.

Radio-frequency identification (RFID) tags are another known mechanismfor tracking items. In contrast to barcodes, RFID tags do not usuallyrequire manual scanning. An RFID system typically includes an RFIDreader and an RFID device such as a tag or label. The RFID readertransmits a Radio-Frequency (“RF”) carrier signal to the RFID device. Inoperation, the RFID device may respond to the RF carrier signal (orinterrogator signal) with a data response signal (or authenticationreply signal) encoded with information stored on the RFID device.Conventionally, RFID devices may store information such as a uniqueidentifier or an Electronic Product Code (“EPC”) associated with anarticle or item.

To address these requirements, a system is needed that may monitor dataregarding objects and efficiently extend visibility of such objects.Thus, there remains a need for an improved system that may provide moreextensive and robust identification and tracking of items in a warehouseenvironment and to do so in a cost effective manner.

SUMMARY

To improve the state of the art, disclosed herein is a warehouseinventory management system, and methods of use thereof, utilizing novelfunctionalities. The system includes a global inventory databasesubsystem for cataloging a plurality of inventory items, each of theitems identified by at least a unique identification code, such as anElectronic Product Code (EPC); and, a radio frequency identification(RFID) interrogator subsystem, the RF interrogator subsystem operativeto read RFID tags associated with each of the plurality of inventoryitems, wherein each of the RFID tags is programmed with at least aunique identification code for its associated item. The disclosed systemand methods provide functionality for improved single itemidentification/location, verification of shipping and receiving of aplurality of inventory items, and inventory operations utilizing aplurality of RFID interrogators mountable on warehouse rackingassemblies. The warehouse inventory management system can also include amotion detection subsystem for detecting and identifying any inventoryitems moving from a first physical zone to a second physical zone. Adisclosed system and method for simulating the operation of thewarehouse inventory management system can be used to design and optimizethe system.

In general, the disclosed methods for maintaining inventory data in awarehouse inventory management system include the functions of utilizingan RFID interrogator subsystem to read RFID tags associated withinventory items. Is such an exemplary system, the RFID interrogatorsubsystem can be configured to receive, from the global inventorydatabase subsystem, at least one unique identification code for an item;scan the RFID tags of items contained at a physical location; and,report, to the global inventory database subsystem, whether the itemassociated with the at least one unique identification code is presentin the warehouse and the physical location of the item. The RFIDinterrogator subsystem is further operable to receive a Shipping Notice(SN) from the global inventory database subsystem, wherein the SNidentifies a plurality of new inventory items to be received at thewarehouse; and, scan the RFID tags of all items contained in a shipment,whereby receipt of all expected items identified in the SN can beverified.

The RFID interrogator subsystem can be configured to selectively confirmwhen all items within the warehouse have been scanned and can beconfigured to send a report to the global inventory database subsystemthat identifies at least one of the presence or absence of each of theplurality of items at the physical location. The physical location canbe, for example, the position of the item on a rack of the warehouserack assembly. Thus, it is contemplated that the report can cause theglobal inventory database subsystem to update the physical location ofones of the plurality of items scanned by the RF interrogator subsystem.As one skilled in the art will appreciate, the global inventory databasesubsystem can maintain at least one attribute for each of the pluralityof inventory items.

An RFID interrogator subsystem can comprise a plurality of fixed RFIDinterrogators that are mounted to portions of a respective rack that ispositioned in the warehouse. As one will appreciate, it is contemplatedthat a warehouse will comprise a plurality of racks that are positionedin an array throughout the warehouse floor space. The location of eachof the plurality of fixed RFID interrogators for each rack has a knowngeospatial relationship that is stored within the global inventorydatabase subsystem. Thus, the global inventory database subsystem knowsthe relative position of each of the plurality of fixed RFIDinterrogators for each rack and therefore also knows the relativepositions of each of the plurality of fixed RFID interrogators for allthe racks positioned in the warehouse. Optionally, the plurality of RFIDinterrogators forming the RFID interrogator subsystem can include atleast one handheld RFID interrogator, each operative to share dataassociated with scanned items with the global inventory databasesubsystem.

Optionally, a plurality of RFID tags can be positioned on eachrespective rack in the warehouse. The rack mounted RFID tags are notassociated with an inventory item, but rather are positioned on each ofthe respective racks in a known positional array that is stored with theglobal inventory database subsystem. It is contemplated that thecombination of the known position of the respective fixed RFIDinterrogators on each rack and the known position of the respective rackmounted RFID tags on each rack will aid in positionally fixing thegeospatial location of inventory items within the warehouse environment.

Optionally, it is contemplated that the plurality of RFID interrogatorscan be configured to share data associated with scanned items, the dataincluding at least the unique identification code for each scanned item.Exemplarily, the data associated with scanned items can include the dateand time of a scanning event so that the warehouse inventory managementsystem can synchronize data associated with each inventory item receivedfrom different RFID interrogators. In some embodiments, the data isshared between RFID interrogators in real-time; the data can be directlyshared between the RFID interrogators via a wireless connection orindirectly via the global inventory database subsystem.

The warehouse inventory management system can further comprise a motiondetection subsystem, such as, for example, an infrared sensor, amicrowave sensor, an ultrasonic sensor, or a video camera sensor. In oneaspect, it is contemplated that a motion detection subsystem can bemountable in at least one of the fixed RFID interrogators that aremounted on the racks in the warehouse. In operation, the motiondetection subsystem can be configured to detect movement within a regionbetween a first physical zone and a second physical zone; enabling, inresponse to detecting movement, the RFID interrogator subsystem toidentify any inventory items moving from the first physical zone to thesecond physical zone; and, reporting, to the global inventory databasesubsystem, the identity of each identified inventory item, whereby theglobal inventory database system can update the physical location ofeach item from the first physical zone to the second physical zone.

Optionally, it is contemplated that fixed RFID interrogators positionedtherein the warehouse racks can be positioned such that their associatedread zones are non-overlapping, e.g., a first fixed RFID interrogator ina first rack and a second fixed RFID interrogator in a second, nearbyrack. In this operational scenario, movement of an item from a firstphysical zone proximate the first fixed RFID interrogator to a secondphysical zone proximate the second fixed RFID interrogator is indicatedif the first fixed RFID interrogator reads an RFID tag of the itembefore the second fixed RFID interrogator, and from the second physicalzone to the first physical zone if the second fixed RFID interrogatorreads the RFID tag of the item before the first fixed RFID interrogator.

Optionally, and as described in detail herein, the adaptive inventorymanagement system for use in a materials handling facility can include aplurality of receptacles, a global inventory management system, and anRFID interrogator subsystem. In this aspect, the plurality ofreceptacles, such as exemplified racks, can be configured to receive oneor more items of a plurality of items, wherein each of the plurality ofitems is associated with a Radio Frequency Identification (RFID) tag. Inthis aspect, it is contemplated that each RFID tag stores a uniqueidentifier as described herein.

Is this aspect, the global inventory database subsystem has a processingsystem having at least one memory of the processing system that isconfigured to store program instructions. The RFID interrogatorsubsystem includes a plurality of RFID interrogators and it iscontemplated that at least one of the RFID interrogators can be mountedin a fixed geospatial location in the materials handling facility.Further, each of the RFID interrogators can be configured to read theunique identifier of the RFID tag associated with each of the pluralityof items that are within a defined boundary of at least one scan zonegenerated by the respective RFID interrogator and to subsequentlycommunicate the unique identifier of the each scanned RFID tagidentified within each scan zone of the respective RFID interrogator tothe processing system.

Thus, in operation, the at least one memory of the processing system canbe configured to store program instructions that when executed cause thedefined boundaries each scan zone for each RFID interrogators to beselectively configured to effect user desired levels of fidelity and/orresolution with respect to the generated unique identifier of the eachscanned RFID tag within a defined space of the materials handlingfacility.

In optional aspects, the defined boundaries each of scan zone for eachRFID interrogators can be configured such that boundaries of therespective RFID interrogators do not overlap or, alternatively or incombination, the defined boundaries each of scan zone for each RFIDinterrogator is user configurable such that at least portions of thedefined boundaries of the respective RFID interrogators overlap with atleast adjacent or otherwise selected RFID interrogators to define atleast one overlapping scan zone. In this aspect, each overlapping scanzone and the associated RFID identifier data therefrom are created fromRFID identifier data received from each scan of the respective scanzones of the respective selected RFID interrogators, and the RFIDidentifier data of the each scanned RFID tag identified withinoverlapping scan zone is communicated to the processing system.

It is further contemplated that, in operation, the scan zones projectedby each RFID interrogators can be selectively configured to effect userdesired levels of fidelity and/or resolution via the use of one or moreconfigurable program options to include at least one of: changing thenumber of RFID interrogators to change the number of scan zonesprojected by the RFID interrogators within the defined space of thematerials handling facility; changing the use of overlapping scan zonesprojected by the RFID interrogators within the defined space of thematerials handling facility; changing the use of signal strength orphase shifting modalities within respective scan zones projected by theRFID interrogators within the defined space of the materials handlingfacility; changing the use of steerable antenna technologies in eachRFID interrogator to create multiple spaced scan zones generated fromeach of the RFID interrogators within the defined space of the materialshandling facility; or changing the use of steerable antenna technologiesin the RFID interrogators within the defined space of the materialshandling facility to create multiple overlapping scan zones from each ofthe RFID interrogators.

Thus, as described herein, it is contemplated that the user desiredlevels of fidelity and/or resolution can be selectively increased viathe use of one or more configurable program options to include at leastone of: increasing the number of RFID interrogators to increase thenumber of scan zones projected by the RFID interrogators within thedefined space of the materials handling facility; increasing the use ofoverlapping scan zones projected by the RFID interrogators within thedefined space of the materials handling facility; increasing the use ofsignal strength or phase shifting modalities within respective scanzones projected by the RFID interrogators within the defined space ofthe materials handling facility; increasing the use of steerable antennatechnologies in each RFID interrogator to increase the number of createdmultiple spaced scan zones generated from each of the RFID interrogatorswithin the defined space of the materials handling facility; orincreasing the use of steerable antenna technologies in the RFIDinterrogators within the defined space of the materials handlingfacility to increase the number of created multiple overlapping scanzones from each of the RFID interrogators.

Still other aspects, embodiments, and advantages of these exemplaryaspects and embodiments, are discussed in detail below. Moreover, it isto be understood that both the foregoing information and the followingdetailed description are merely illustrative examples of various aspectsand embodiments, and are intended to provide an overview or frameworkfor understanding the nature and character of the claimed aspects andembodiments. Accordingly, these and other objects, along with advantagesand features of the present invention herein disclosed, will becomeapparent through reference to the following description and theaccompanying drawings. Furthermore, it is to be understood that thefeatures of the various embodiments described herein are not mutuallyexclusive and can exist in various combinations and permutations.

BRIEF DESCRIPTION OF THE DRAWINGS

The accompanying drawings, which are included to provide a furtherunderstanding of the embodiments of the present disclosure, areincorporated in and constitute a part of this specification, illustrateembodiments of the present disclosure, and together with the detaileddescription, serve to explain the principles of the embodimentsdiscussed herein. No attempt is made to show structural details of thisdisclosure in more detail than can be necessary for a fundamentalunderstanding of the exemplary embodiments discussed herein and thevarious ways in which they can be practiced. According to commonpractice, the various features of the drawings discussed below are notnecessarily drawn to scale. Dimensions of various features and elementsin the drawings can be expanded or reduced to more clearly illustratethe embodiments of the disclosure.

FIG. 1 schematically illustrates an example of a warehouse inventorymanagement system.

FIG. 2 schematically illustrates an example of an RFID interrogatorsubsystem and global inventory database subsystem of a warehouseinventory management system.

FIG. 3 schematically illustrates an example of a warehouse inventorymanagement system; showing a plurality of conventional warehouse racksor H-racks positioned in an array on the floor of the facility orwarehouse.

FIG. 4 schematically illustrates a first embodiment of a fixed RFIDinterrogator positioned in a conventional warehouse H-rack.

FIG. 5 is an expanded schematic view of the fixed RFID interrogator ofFIG. 4 positioned in a conventional warehouse rack.

FIG. 6 schematically illustrates a plurality of the fixed RFIDinterrogators of FIG. 4 positioned in a conventional warehouse H-rack.

FIG. 7 schematically illustrates the plurality of fixed RFIDinterrogators of FIG. 6 and a plurality of rack-mounted RFID tagspositioned in conventional warehouse racks.

FIG. 8 schematically illustrates a second exemplary embodiment of afixed RFID interrogator positioned in a conventional warehouse H-rack.

FIG. 9 is an expanded schematic view of the fixed RFID interrogator ofFIG. 8 positioned in a conventional warehouse rack.

FIG. 10 is an expanded schematic view of the fixed RFID interrogator ofFIG. 9 positioned in a conventional warehouse rack, showing a portion ofthe cover removed to display a portion of an antenna.

FIG. 11 schematically illustrates a plurality of the fixed RFIDinterrogators of FIG. 8 positioned in a conventional warehouse H-rack.

FIG. 12 schematically illustrates a fixed RFID interrogators of FIG. 8being coupled in a daisy-chain manner to serially communicate power toconnected fixed RFID interrogators, and showing the plurality ofelectrically coupled fixed RFID interrogators being further electricallycoupled to a source of main and/or battery power.

FIG. 13 schematically illustrates an example of a fixed RFIDinterrogator.

FIG. 14 illustrates an example warehouse floorplan.

FIG. 15 illustrates example scan zones in the example warehouse of FIG.14.

FIG. 16 illustrates four RFID interrogators installed on a racking unitthat would scan the individual bay or shelf, in an embodiment.

FIG. 17 illustrates a process flow, in an embodiment.

FIG. 18 illustrates an example RFID interrogator (reader)/hub system.

FIG. 19 illustrates structure of a database system, in an embodiment.

FIG. 20 illustrates a process flow, in an embodiment.

FIG. 21 illustrates an example of a basic system architecture with twozones, one hub, and four assets.

FIG. 22 illustrates a process flow for the system of FIG. 21, in anembodiment.

FIG. 23 illustrates an example of a basic system schematic of an RFIDinterrogator, in an embodiment.

FIG. 24 illustrates an example of a basic of a low versus high fidelitysystem, in an embodiment.

FIG. 25 illustrates an example set up for a warehouse shelf withmultiple RFID interrogators.

FIG. 26 illustrates a multitude of zones achieved through placement ofRFID interrogators, by varying quantity of RFID interrogators, byvarying signal strength of the respective RFID interrogators, and/or byvarying azimuth orientation of RFID interrogators.

DETAILED DESCRIPTION

The present invention can be understood more readily by reference to thefollowing detailed description, examples, drawings, and claims, andtheir previous and following description. However, before the presentdevices, systems, and/or methods are disclosed and described, it is tobe understood that this invention is not limited to the specificdevices, systems, and/or methods disclosed unless otherwise specified,and, as such, can, of course, vary. It is also to be understood that theterminology used herein is for the purpose of describing particularaspects only and is not intended to be limiting.

The following description of the invention is provided as an enablingteaching of the invention in its best, currently known embodiment. Tothis end, those skilled in the relevant art will recognize andappreciate that many changes can be made to the various aspects of theinvention described herein, while still obtaining the beneficial resultsof the present invention. It will also be apparent that some of thedesired benefits of the present invention can be obtained by selectingsome of the features of the present invention without utilizing otherfeatures. Accordingly, those who work in the art will recognize thatmany modifications and adaptations to the present invention are possibleand can even be desirable in certain circumstances and are a part of thepresent invention. Thus, the following description is provided asillustrative of the principles of the present invention and not inlimitation thereof.

As used throughout, the singular forms “a,” “an” and “the” includeplural referents unless the context clearly dictates otherwise. Thus,for example, reference to “a fixed RFID interrogator” can include two ormore such fixed RFID interrogators unless the context indicatesotherwise.

Ranges can be expressed herein as from “about” one particular value,and/or to “about” another particular value. When such a range isexpressed, another aspect includes from the one particular value and/orto the other particular value. Similarly, when values are expressed asapproximations, by use of the antecedent “about,” it will be understoodthat the particular value forms another aspect. It will be furtherunderstood that the endpoints of each of the ranges are significant bothin relation to the other endpoint, and independently of the otherendpoint.

As used herein, the terms “optional” or “optionally” mean that thesubsequently described event or circumstance can or cannot occur, andthat the description includes instances where said event or circumstanceoccurs and instances where it does not.

The word “or” as used herein means any one member of a particular listand also includes any combination of members of that list. Further, oneshould note that conditional language, such as, among others, “can,”“could,” “might,” or “can,” unless specifically stated otherwise, orotherwise understood within the context as used, is generally intendedto convey that certain aspects include, while other aspects do notinclude, certain features, elements and/or steps. Thus, such conditionallanguage is not generally intended to imply that features, elementsand/or steps are in any way required for one or more particular aspectsor that one or more particular aspects necessarily include logic fordeciding, with or without user input or prompting, whether thesefeatures, elements and/or steps are included or are to be performed inany particular embodiment.

The phraseology and terminology used herein is for the purpose ofdescription and should not be regarded as limiting. As used herein, theterm “plurality” refers to two or more items or components. The terms“comprising,” “including,” “carrying,” “having,” “containing,” and“involving,” whether in the written description or the claims and thelike, are open-ended terms, i.e., to mean “including but not limitedto.” Thus, the use of such terms is meant to encompass the items listedthereafter, and equivalents thereof, as well as additional items. Onlythe transitional phrases “consisting of” and “consisting essentiallyof,” are closed or semi-closed transitional phrases, respectively, withrespect to any claims. Use of ordinal terms such as “first,” “second,”“third,” and the like in the claims to modify a claim element does notby itself connote any priority, precedence, or order of one claimelement over another or the temporal order in which acts of a method areperformed, but are used merely as labels to distinguish one claimelement having a certain name from another element having a same name(but for use of the ordinal term) to distinguish claim elements.

Disclosed are components that can be used to perform the disclosedmethods and systems. These and other components are disclosed herein,and it is understood that when combinations, subsets, interactions,groups, etc. of these components are disclosed that while specificreference to each various individual and collective combinations andpermutation of these cannot be explicitly disclosed, each isspecifically contemplated and described herein, for all methods andsystems. This applies to all aspects of this application including, butnot limited to, steps in disclosed methods. Thus, if there are a varietyof additional steps that can be performed it is understood that each ofthese additional steps can be performed with any specific embodiment orcombination of embodiments of the disclosed methods.

The present methods and systems can be understood more readily byreference to the following detailed description of preferred embodimentsand the examples included therein and to the Figures and their previousand following description.

With regards to the adaptive inventory management system describedherein, two definitions are established for the respective terms“fidelity” and “resolution.” Fidelity, as defined herein, refers to therespective and selective granularity with the result to the numberand/or identification the RFID tags that are detected within aparticular scanned zone or a particular defined space. Within thewarehouse inventory management system, “fidelity” answers the basicquestion of: “what RFID tagged items are present in the scanned area,”or, more particularly, “how many items and which specific items(according to associated RFID tags) are in a scanned zone or definedspace.” Resolution, as defined herein, refers to the respective andselective geo-spatial location of the RFID tags that are detected withina particular scanned zone or a particular defined space. Within thewarehouse inventory management system, “resolution” answers the basicquestion of: “where are the RFID tagged items physically located withinthe scanned area,” or, more particularly, “in which zone or definedspace is a specific item (according to an associated RFID tag)physically located.”

Radio frequency identification (RFID) systems utilize RFID reader/writerdevices, also known as RFID interrogators, and RFID tags. Such systemscan be used to locate and identify items to which the tags are attached;they are particularly useful in product-related industries for trackinginventory items through manufacture, distribution and sale. An RFID tagcan be affixed to an individual product, its package, or a container formultiple products or packages.

An RFID tag typically includes an antenna section, a radio section, apower-management section, and frequently a non-volatile memory. SomeRFID tags include an energy storage device, such as a battery. It iscontemplated that the RFID tags used in a warehouse facility will beconfigured conventionally and, as such, will be passive tags that aretypically powered solely by the RF signal they receive and will notinclude an energy storage device (e.g., a battery).

Conventional RFID inventory management techniques utilize an RFIDinterrogator to inventory one or more items having RFID tags, whereinventorying involves at least singulating a tag and receiving a uniqueidentifier from the tag. As used herein, “singulated” is defined as anRFID interrogator singling-out one tag, potentially from among multipletags and “identifier” is defined as a number identifying the tag or theitem to which the tag is attached, such as a tag identifier (TID) or anelectronic product code (EPC). Conventionally, an RFID interrogatortransmits a modulated RF command, receives a tag reply, and can, ifdesired, transmit an RF acknowledgement signal responsive to the tagreply. A tag that senses the interrogating RF wave responds bytransmitting back another RF wave; the tag either generates thetransmitted RF wave or reflects back a portion of the interrogating RFwave in a process known as backscatter. The reflected-back RF wave canencode data stored in the tag, such as the EPC. For example, theresponse is decoded by the RFID interrogator, and can thereby identify,count, or otherwise interact with the associated item. In one aspect,the decoded data can denote geospatial location of the item to which theRFID tag is attached or other desired attribute or status. The systemsand methods described hereinafter make use of such data to improve theoperation and use of warehouse inventory management systems.

In various embodiments, a warehouse inventory management system for awarehouse has a plurality of racks positioned in an array on a floor ofthe warehouse. The warehouse inventory management system has a globalinventory database subsystem for cataloging a plurality of inventoryitems, each item being identified by at least a unique identificationcode and a physical location within the warehouse, and a radio frequencyidentification (RFID) interrogator subsystem operative to read RFID tagsassociated with each of the plurality of inventory items. The RFIDinterrogator system includes a plurality of fixed RFID interrogatorsmounted to portions of each rack in the warehouse that are configured tocommunicate at least location and identification data to the globalinventory database subsystem for determination of the geospatiallocation of inventory items within the warehouse.

Turning now to FIGS. 1-3, an example warehouse inventory managementsystem is shown that includes an RFID interrogator subsystem 10 and aglobal inventory database subsystem 20 for use in a warehouse. As oneskilled in the art will appreciate, the global inventory databasesubsystem 20 (alternately referred to herein as a “server”) can be localor remote; a remote location can be dedicated or cloud-based.

The RFID interrogator subsystem 10 can include a plurality of fixed RFIDinterrogators 12. Each fixed RFID interrogator has an interface to theglobal inventory database subsystem 20, which interface for a fixed RFIDinterrogator can be configured to be wired, wireless, or at leastpartially wireless (e.g., to a local router Wi-Fi router). As will bedescribed more fully hereinafter, it is also contemplated that the RFIDinterrogators can also include a direct wireless connection for thesharing of certain data. Such a connection can be, for example, aBluetooth® wireless connection. In operation, the RFID interrogators areconfigured to selectively interact with RFID tags contained on items(noting that it is contemplated that an RFID tag can be associated on anindividual item, on boxes of items, and the like). Optionally,individual items or boxes of items having RFID tags can also be within acontainer having its own respective RFID tag. Optionally, the pluralityof fixed RFID interrogators can include at least one handheld RFIDinterrogator, each operative to share data associated with scanned itemswith the global inventory database subsystem.

As shown in FIG. 2, the global inventory database subsystem 20 caninclude a processing system having at least one processor 22 and atleast one memory 23, which can be coupled to a non-volatile memorycontaining a database 24 for cataloging information related to aplurality of inventory items; the memory contains instructions which,when executed by the processor, are operative to perform the essential,recommended and/or optional functions in various embodiments of theglobal inventory database subsystem described herein.

As illustrated in FIGS. 4-6 and 8-12, the exemplary RFID interrogatorsubsystem 10 can comprise a plurality of fixed RFID interrogators 12that are mounted to portions of a respective rack 40 that is positionedin the warehouse. Exemplary racks 40 includes the illustratedconventional H-rack, but are not intended to be limited to be limited tosuch a H-rack. Rather, any conventional geospatially fixed position rack40 can be utilized in the present warehouse inventory management system.As one will appreciate, and as shown in FIG. 3, it is contemplated thata warehouse will comprise a plurality of racks that are positioned in anarray throughout the warehouse floor space. The geospatial location ofeach of the plurality of fixed RFID interrogators 12 for each rack has aknown geospatial relationship that is stored within the global inventorydatabase subsystem 20. Thus, the global inventory database subsystemknows the relative position of each of the plurality of fixed RFIDinterrogators 12 for each respective rack 40 and therefore also knowsthe relative positions of each of the plurality of fixed RFIDinterrogators 12 for all the racks 40 positioned in the warehouse. Theexemplary RFID interrogator subsystem 10 can further comprise at leastone hub that is configured to act as a network node, which is configuredto relay information to and from the individual each fixed RFIDinterrogator device 12 to the global inventory database subsystem 20. Inone exemplary aspect, the fixed RFID interrogator device 12 cancommunicate wirelessly with the hub, and the hub can then communicate tothe global inventory database subsystem 20. either by Ethernet, Wi-Fi,cellular, or the like.

It is contemplated that each fixed RFID interrogator device 12 (e.g.,the RFID interrogator device shown in FIG. 13) of the RFID interrogatorsubsystem 10 can individually have a processing system having at leastone processor 14 and at least one memory 16, a baseband circuit 17 withtransmitter TX and receiver RX, and an RF circuit 15 with circulator,which are coupled to an antenna 18 for interacting with RFID tagsaffixed to items, boxes or containers. Optionally, the antenna 18 can beconfigured to be interchangeable or replaceable to allow for operatorselective scanning zones for a respective fixed RFID interrogator device12. It is further contemplated that the memory 16 can containinstructions which, when executed by the processor 14, are operative toperform the essential and optional functions of the RFID interrogators12 described herein.

Optionally, each fixed RFID interrogator device 12 can be configured tofurther include circuitry or components, e.g., a phase shifter, that areconfigured to change the inductance of the antenna 18, thereby causing aphase of an electromagnetic field emitted by the antenna 18 to vary withrespect to its length. Because the strength of an RFID signal emitted byan RFID tag within the presence of an electromagnetic field is typicallydependent upon the strength of the electromagnetic field, varying thephase of the electromagnetic field at various intervals of time, e.g.,by phase angles of up to ninety degrees (90°) or one hundred eightydegrees (180°) in either direction with respect to a length of theantenna 18 at predetermined intervals, increases the likelihood thatRFID signals of sufficient strength will be transmitted by RFID tagsborne by each of the items positioned on the respective racks in thewarehouse within a predefined range of antenna 18, regardless of wherethe RFID tag is located.

For example, shifting a phase of a rectified standing wave of anelectromagnetic field back and forth with respect to the length ofantenna 18 can cause points of peak amplitude and points of minimumamplitude (e.g., peaks and valleys) of the rectified standing wave tomove along the length of antenna 18, ensuring that points where thestrength of the electromagnetic field is at a minimum, e.g., points ofminimum amplitude of the rectified standing wave, never remain in thesame place rack for an extended duration, and that every RFID tagpositioned on the respective racks in the warehouse within a predefinedrange of antenna 18 experiences a sufficiently strong electromagneticfield to cause an RFID signal to be emitted thereby. Thus, where astrength of an RFID signal transmitted by an RFID tag to an antenna 18remains above a threshold or limit for a predetermined period of time,an item bearing the RFID tag can be determined to be located on a rackprovided within the predefined range of the antenna 18. Varying thephase of the electromagnetic field may also enable user selectablelevels of fidelity and or resolution for an item bearing an RFID tag ona support bar or arm to be determined or predicted based on thestrengths of RFID signals received from the RFID tag.

Optionally, each fixed RFID interrogator device 12 can be configured tofurther include circuitry or components, e.g., an antenna azimuthshifter, that are configured to change relative scanned angularorientation or azimuth of the antenna 18, thereby causing theelectromagnetic field emitted by the antenna 18 to propagate along thechanged azimuth axis of the antenna. Varying the azimuth of theelectromagnetic field may also enable user selectable levels of fidelityand or resolution for an item bearing an RFID tag on a support bar orarm to be determined or predicted based on the RFID signals receivedfrom the RFID tag from the use of iterated azimuth readings receivedfrom a single RFID interrogator.

In various aspects, each fixed RFID interrogator device 12 of the RFIDinterrogator subsystem 10 can further include a frame that is configuredto support the antenna 18 and the associated processing system. Suchframe can be housed within a durable plastic housing 19 for protectionand RF transparency. Further, as illustrated in FIGS. 4-6, each fixedRFID interrogator can further comprise a rail system 50 that is coupledto the frame and which is, for example, configured to be selectivelycoupled to the teardrop openings that are present in opposing verticalrisers of conventional industry rack systems. As one will appreciate, itis contemplated that the rail system could be fixed to the conventionalracks via mechanical connections that would accommodate various brandsof racks and their openings. Further, different lengths of arms oradjustable arms for different depths of racking, or the system couldmount to one vertical riser of the conventional industry rack systems asshown in FIGS. 8-12.

In an optional aspect, not illustrated herein, the fixed RFIDinterrogator device 12 can be mounted to the underside of the wiredecking of the conventional rack system to allow for a “look up” or“look down” orientation of the interrogator antenna 18. For example, inthis aspect, the fixed RFID interrogator device 12 can be mounted to theunderside of the wire decking in the space spaced defined between thecrossbeams of the rack such that the mounted fixed RFID interrogatordevice 12 would be out of the way of stored inventory.

It is contemplated that each fixed RFID interrogator device 12 can beconfigured to operate from battery power or optional standard mainspower, which allows the possibilities of using the system in remotelocations where standard power is not available. As one will appreciate,battery operated RFID interrogator devices would make power dropsunnecessary, and the contemplated use of Wi-Fi, Bluetooth and cellulartechnologies would eliminate cable runs, which allows for simpleinstallation and reconfiguration of the system. In one optional aspectshown in FIG. 12, a plurality of fixed RFID interrogators being mountedto one vertical riser of a conventional industry rack can beelectrically coupled in a daisy-chain manner to allow for serialcommunication of electrical power to the mounted fixed RFIDinterrogators. As further exemplarily illustrated, the plurality ofelectrically coupled fixed RFID interrogators can further be configuredto be electrically coupled to a source of main and/or battery power.

Optionally, and as shown in FIG. 7, it is contemplated that thewarehouse inventory management system can further include a plurality ofRFID tags positioned on each respective rack in the warehouse. The rackmounted RFID tags are not intended to be associated with a respectiveinventory item, but rather are positioned on each of the respectiveracks in a known positional array that is stored with the globalinventory database subsystem. It is contemplated that the combination ofthe known position of the respective fixed RFID interrogators on eachrack and the known position of the respective rack mounted RFID tags oneach rack will aid in positionally fixing and/or increasing the fidelityof the geospatial location of inventory items within the warehouseenvironment.

In a warehouse (also referred to as a “distribution center”), aninventory management system must perform many functions, includingreceiving, inbound auditing, pick processing, pack auditing, andshipping verification. Upon receiving a shipment, an RFID interrogatorcan read an RFID tag on each container, or RFID tags of each item in acontainer, to be checked against an advance shipping notice (“SN”);discrepancies between what is received and the SN can be reported to theinventory management system.

As described supra, the global inventory database subsystem 20 catalogsall inventory items within a warehouse, and can generate an SN,identifying one or more items, each by a unique identification code. TheRFID interrogator subsystem 10 then is used to scan the RFID tags ofitems contained within the warehouse or a desired selected portion ofthe warehouse. Following the scanning of items, a report can be sent tothe global inventory database system, identifying which items wereidentified/counted and the physical location of the respective itemswithin the warehouse.

In various aspects, the fixed RFID interrogators can share dataassociated with scanned items, either directly or indirectly. A directwireless connection can be, for example, a Bluetooth® wirelessconnection. Alternatively, or additionally, each fixed RFID interrogatorcan share data indirectly through the global inventory databasesubsystem 20 by the immediate reporting of each scanned item, which canthen be pushed to, or pulled by, another fixed RFID interrogator. Theshared data includes at least the unique identification code for eachscanned item; the geospatial location data associated with each scanneditem to include the date and time of a scanning event, whereby thewarehouse inventory management system can synchronize data associatedwith each inventory item received from different fixed RFIDinterrogators. For example, the global inventory database subsystem 20should maintain at least the most recent location, together with thedate and time; in some embodiments, maintaining a record of data fromall scanning events can be helpful for inventory management ordetermining the basis for discrepancies. One skilled in the art willappreciate that maintaining a time based record of the scanned items canbe used to create a history of an item's movement through a warehouse.This time based record can be used to process inventory bottlenecks,identify aging or perishable inventory, alert operators of pilfereditems and the like.

The warehouse inventory management system 10 can further comprise amotion detection subsystem, such as, for example, an infrared sensor, amicrowave sensor, an ultrasonic sensor, or a video camera sensor that isin communication with the global inventory database subsystem 20. In oneaspect, it is contemplated that a motion detection subsystem can bemountable in at least one of the fixed RFID interrogators that aremounted on the racks in the warehouse. Optionally, the motion detectionsubsystem can be mountable as desired in the warehouse space, e.g.,proximate door entrances, and the like. In operation, the motiondetection subsystem can be configured to detect movement within a regionbetween a first physical zone and a second physical zone; enabling, inresponse to detecting movement, the RFID interrogator subsystem toidentify inventory items moving from the first physical zone to thesecond physical zone; and, reporting, to the global inventory databasesubsystem, the identity of each identified inventory item, whereby theglobal inventory database system can update the physical location ofeach item from the first physical zone to the second physical zone. Asused herein, “enabled” or “enabling” means to either activate the RFIDinterrogator subsystem (if generally inactivated) or to allow it tointerrogate RFID tags (if generally activated). Once activated orotherwise allowed to interrogate RFID tags, the RFID interrogatorsubsystem identifies inventory item(s) moving from the first physicalzone to the second physical zone; the identity of such items are thenreported to the global inventory database subsystem, which can thenupdate the location of each inventory item moved between the physicalzones.

As described, the global inventory database subsystem 20 can beconfigured to activate a scan, or to prevent a scan, depending on theneed and or event triggered by the motion detection subsystem. Invarious examples, and not meant to be limiting, motion detected at aback door proximate a motion detection sensor, can trigger a scan fortheft, or general movement in the warehouse sensed by the motiondetection subsystem could suggest that an item is being moved.

It is also contemplated that the global inventory database subsystem 20can be configured to use timers to trigger scans, push commands from auser, or other such combination.

Optionally, it is contemplated that fixed RFID interrogators 12positioned therein the warehouse racks can be positioned such that theirassociated read zones are non-overlapping, e.g., the read zones of afirst fixed RFID interrogator in a first rack non-overlapping with theread zones of a second fixed RFID interrogator in a second, nearby rack.In this operational scenario, movement of an item from a first physicalzone proximate the first fixed RFID interrogator to a second physicalzone proximate the second fixed RFID interrogator is indicated if thefirst fixed RFID interrogator reads an RFID tag of the item before thesecond fixed RFID interrogator, and from the second physical zone to thefirst physical zone if the second fixed RFID interrogator reads the RFIDtag of the item before the first fixed RFID interrogator.

Still further, it is optionally contemplated that fixed RFIDinterrogators 12 positioned therein the warehouse racks can bepositioned such that their associated read zones are positioned topurposefully overlap, e.g., a plurality of fixed RFID interrogatorsconfigured to have overlapping read zones. In this example, if an itemis registered in all three of the overlapping read zones, the item mustbe in a very precise geo-spatial region. However, if the item isregistered in only two of the three overlapping read zones, the itemmust be a different but specific geo-spatial region, and if the item isregistered in only one of the three overlapping read zones, the itemmust be a yet another different but specific geo-spatial region.

The exemplary warehouse inventory management system can be configured toaddress multiple types of businesses. As one will appreciate, everybusiness has slightly different needs and expectations, and thewarehouse inventory management system is configured to be adaptable toaddress the respective business needs and expectations as they changeover time.

An exemplary methodology in configuring the warehouse inventorymanagement system to meet the requirements of the user can include aninitial step of completing a site assessment. In this phase, the usercan identify the expected outcomes of the warehouse inventory managementsystem and take into account at least one of the business,technological, IT, facility, and HR factors. This site assessment stepcan involve the development of a customer installation plan that canidentify key factors, can describe the installation requirements, and/orcan provides an invoice bill of material for ordering hardware.

In the site assessment step, it is desired to identify the particularsof the items that the business wants to be tagged and tracked. In onenon-limiting example, knowing at least one of the quantity, density,transit speed, physical composition, and environmental context of theintended tracked items can help in determining the appropriate RDID tagto attach to the items.

It is further desired to identify the intended monitored space in thesite assessment step. Identifying the intended monitored space allowsfor the determination of the physical and radio frequency (RF)characteristics of the space to be monitored (to include determiningpotential RF interference so that background noise levels that couldinterfere with RF technology scanning can be identified), along with atleast one user-defined zones within each space. In this aspect, a zoneis a location that warehouse inventory management system will report asa location for an item. As one will appreciate, the number and size ofvarious zones can determine the amount of RFID interrogators 12 and hubsthat would needed to build out the warehouse inventory management systemto meet the respective business' operational needs.

In this site assessment step, the warehouse inventory management systemcan also determine the users and their profiles. The warehouse inventorymanagement system can be configured to allow for controlled access todata and this can be set up with permission roles for different users,which allows for different users to have different visibility/accesswithin the warehouse inventory management system 10.

In a subsequent installation step, the required hardware, i.e., devicesand systems supporting the exemplary RFID interrogator subsystem 10 andthe global inventory database subsystem 20 is installed at the facilitylocations according to the customer installation plan. For example,fixed RFID interrogator devices 12 and hubs can be positioned at desiredlocations with facility with the intent of having the exemplary RFIDinterrogator subsystem 10 presenting low visibility and minimal impact.This allows for the mitigation of damage to system component and can aidin eliminating potential equipment interference to the normal functionsof the business.

Further in the installation step, the exemplary RFID interrogatorsubsystem 10 and the global inventory database subsystem 20 isconfigured and the hardware is brought online. The fixed RFIDinterrogator devices 12 and hubs are all configured and operationallytested. In one non-limiting aspect, because it is contemplated that theexemplary warehouse inventory management system will be a browser basedapplication, the warehouse inventory management system would not requirea device-level installation.

In a subsequent user configuration step, the client or site can becreated within the warehouse inventory management system and thensubsequent users can be created to provide access to the data. It iscontemplated that in this user configuration step, the user will loginto the warehouse inventory management system and identify theproduct/item/asset category and the warehouse inventory managementsystem will automatically provide the naming templates, which can beuser customizable. In operation, the user will provide the necessaryinformation and enter in the templates and, when data entry is completedand confirmed for accuracy, the warehouse inventory management systemwill create an electronic product code (epc) and associate all dataentry to this epc within a secure database. Further, it is contemplatedthat a printer can then be used to print a RF-enabled tag with the epccoded into its internal circuitry. It is further contemplated thatoptionally additional human readable item information (bar codeoptional) can be printed on the label. Conventional RF printers canprint ink-based data on the RF-enabled tag for a user to read, but canalso rewrite a RF-enabled tag with custom data.

In a tracking sub-step of the user configuration step, the user appliesa label to an item and, subsequently, if the labeled item is positionedwithin at least one of the warehouse inventory management system zonesand a scan is initiated the warehouse inventory management system willreport back the location and time stamp of the item. In variousexemplary aspects, labels can be integrated into containers, pouches,etc. and be re-used and recoded, and, depending on range and trackingresolution required, active tags can be used by the warehouse inventorymanagement system.

Optionally, in a system functionality step, scan zones can be created orotherwise configured to differentiate between ambient storage and coldstorage. Exemplarily, RFID interrogator devices 12 can be placed aboveand/or on the sides of entry/exit points to track items entering orleaving a building/facility. Optionally, the RFID interrogator devices12 can be motion or event activated. It is further contemplated that thewarehouse inventory management system can be configured to allow for theconduct of scans by the on a recurring or otherwise identified timelineor schedule.

In a further optional aspect, in the system functionality step, scanzones can be created by the exemplary RFID interrogator subsystem 10 andthe global inventory database subsystem 20. As described herein, it iscontemplated that scan zones can be configured to be user-customizable.For example, scan zones can be created or otherwise configured fordesired fidelity and/or resolution via the use of one or moreconfigurable options to include at least one of: increasing/decreasingnumbers of RFID interrogator devices 12 within the defined warehousespace, increasing/decreasing the use of multiple scanned zones and ormultiple overlapping scanned zones; increasing/decreasing the use ofsignal strength or phase shifting modalities within a respective scanzone; and/or increasing/decreasing the use of steerable antennatechnologies in the RFID interrogator devices 12 to create multiplescanned zones from each of the RFID interrogator devices 12.

As described above, it is contemplated that the resolution and fidelityof the warehouse inventory management system can be modified and/orupgraded as desired by the user. The addition of additional RFIDinterrogator devices 12 and/or the use of overlapping zones, whichallows for sensing of an item by two or more RFID interrogator devices12, within the user's configured warehouse inventory management systemcan allow for a user inputted increase in the fidelity and/or resolutionof the particular identified item.

In one additional optional aspect, it is contemplated that the user canmodify the configuration settings of the system to achieve a desireddegree of fidelity and/or resolution for a given warehouse space and agiven, fixed number of RFID interrogator devices 12.

In one aspect the warehouse inventory management system, and moreparticularly the global inventory database subsystem 20, includes asystem operation process (“SOP”) 25 that is described below in detail,with both intended and optional systems. Various system and processembodiments of the SOP 25 with various combinations of above andbelow-described features are considered within the scope of the presentdisclosure.

The intent of SOP 25 in the global inventory database subsystem 20 is toprovide a means to track, locate, aggregate, and communicate inventory,assets, or objects within some defined space. There are many intendedusers for such a process 25, and the SOP 25 provides for user selectablecustomizable solution(s) as the company's warehouse consumable needschange over time.

The SOP process, in one embodiment, starts with defining the area orsite that needs to be monitored. In an example case, the area or sitecould be a warehouse. However, the area or site could be a livestockbarn, a lumberyard, an airport, a retail space, a manufacturingfacility, laboratory, hospital, semi-truck, and the like. This definingstep typically involves creating a map or floorplan of the space. FIG.14 shows an example warehouse floorplan.

As shown, a warehouse 60 exemplarily has racking units 62, an assemblyroom 64 and a building exit 66. The next step is to break up this siteinto zones. Zones are locations or areas within the site that can benamed and identified. Zones, and locations within zones, can be asgranular as needed. If the user need is to provide very preciselocations, then more zones would be optionally created as describedherein. Zones can also overlap to eliminate dead spots as needed or toincrease the desired level of fidelity and/or resolution of the system.In the illustrated example, the warehouse 60 has several warehousestorage racking units 62 with multiple shelves on each rack, it has anexit 66, and it has an assembly room 54 that all need to be zoned.

FIG. 15 illustrates exemplary intended zones 70 (shown as dashed lines)that are defined relative to locations and fixtures in the warehouse 60.At this point in one embodiment process, zones can be named auser-friendly name or something that has meaning to the user, and thisinformation is loaded into the software application of the globalinventory database subsystem 20.

Exemplarily shown, the warehouse space has a zone 70 or multiple zones70 for each racking unit 52, the entrance to the assembly room 64, theassembly room 64 with two overlapping zones 70, and the exit 66 havinginternal and external zones 70. Having a zone 70 at a doorway allows formonitoring of items coming or going through the doorway entrance. Inthis aspect, having two zones 70 at a doorway could be used to monitorthe direction of travel of the RFID identified object, e.g., did theitem leave or enter the warehouse? This is a simplified exemplary aspectbut the system can be selectively configured to be much more granular inanalysis, as desired, to provide for a higher resolution and/orfidelity. For example, each racking unit could have several shelves,each as an individual zone 70, a zone 70 with multiple resolvablelocations within the zone 70, or more than one zone 70 per shelf. Zonescan also be defined somewhat in size and shape by antenna power anddesign, lower power equates to a smaller zone. Also, RF blocking can beselectively utilized to end a specific zone 70. By configuring therespective overlapping zones 70, if an item shows up in two or morezones, then the location has higher fidelity and resolution as it mustbe in the overlap area shared by overlapping zones, which itself may bedefined as a zone or a location within a zone in some embodiments.

The next process step is to place an RFID interrogator device 12 so thatthe intended zones 70 can be scanned. It is contemplated that a zone 70could be comprised of a plurality of an RFID interrogator devices 12 toachieve an adequate degree of fidelity and/or resolution if the productdensity is high or if the nature of the warehouse and materials involvedthat scanning is difficult. It is further contemplated that a zone 70could be comprised of a one or more RFID interrogator devices 12, inwhich each RFID interrogator devices 12 can be configured to scan atleast one zone, or at least a portion of two or more zones (as a userconfigures the global inventory database subsystem 20 for the desiredresolution and/or fidelity of the system output to the user).

In one non-limiting example, FIG. 16 shows four RFID interrogatordevices 12 installed on a racking unit that could be configured to scanthe individual bay or shelf. However, it is also contemplated that theRFID interrogator devices 12 could be mounted and come in many formfactors such as drones or ROV's (remotely operated vehicles), wall orceiling mounted, light fixtures, in rail cars or vehicles, and the like.

FIG. 16 illustrates an exemplary arrangement 72 of four RFIDinterrogators 12 (see also FIG. 6), as readers, at fixed positions. Aspreviously described, increasing or decreasing the number of four RFIDinterrogators 12, in combination with the other optional processdescribed herein can be used to change the desired resolution and/orfidelity of the system.

The next step in the process is to identify the items or assets to betracked and “tag” them. Assets can be many things, as each case willdefine the required level of tagging. In the exemplary warehouse, eachbox of goods gets a unique tag. A tag is an RFID transponder that cancome in many form factors and types. Some are for metal object tagging,some are for animal implanting, some are inexpensive paper tags, whilesome are heavy duty designed to withstand extreme environments. Tags areencoded with a unique identifier called an EPC (Electronic ProductCode). However, tags can also be programmed with a user specific code ifneeded. Tags are then printed, or programmed, and registered within thesoftware application of the global inventory database subsystem 20. Theycould also have barcodes or other user data on the tag if needed. Thesoftware application of the global inventory database subsystem 20 canalso pull from other ERP (Enterprise Resource Planning) oraccounting/inventory management software. For example, if a userpurchases incoming goods through their accounting software, tags couldbe auto generated and integrated in the Venatrust software application.Within the application software database, when a tag is registered, theEPC code on the tag is attached to user friendly names as well. Forexample, a particular EPC (not user friendly) might be attached orassociated in the database to a “Red Jacket” (user friendly). That way auser can see how many “Red Jackets” they have as opposed to a list ofarbitrary EPC's. FIG. 17 shows the general process flow.

FIG. 17 illustrates an exemplary process flow involving zones, RFID tagsand RFID interrogators 12, which is suitable for use at a site and witha system as described herein in various embodiments. Action 74 is zonecreation, in which various zones are identified and RFID interrogatorsare placed to define the zones (and, possibly, locations within zones).Action 76 is tag registration, in which ERP data 78 and user createddata 80 are associated to RFID tags, with appropriate entry ofinformation to the database 82 (e.g., through a database system). Action86 is tag applied to product, in which each RFID tag is associated to acorresponding product (e.g., an item of inventory to be tracked by thesystem), for example by attaching the RFID tag to the product, productpackaging, or container holding product(s). Action 88 is product placedin zones, in which the products with RFID tags applied in the action 86are placed in the various zones that were created in the action 74.

In the action 92 tags scanned by readers, the RFID interrogators 12 scanthe RFID tags, and the system reports the scan information anddeterminations of locations of the RFID tags according to the zones andpossibly locations within zones, to the database 82. The action 92 isrepeated with occurrences of the action 90 product moves around thesite, so that product location and product movement, as determined bythe system, are represented in records in the database 82, withappropriate fidelity and resolution (which may be flexible and vary bylocation, physical set up, system and/or user defined parameters, and soon). Action 84 data communicated to user, involves access(es) to thedatabase 82, and could be implemented through various communicationsprotocols and with various system analyses as appropriate to a specificimplementation.

The next aspect the process is the hub. Hubs are devices thatcommunicate locally with an array of readers. RFID interrogators 12 aredesigned to communicate through either a wired or wireless connection tothe hub, and the hub then communicates to the database and theapplication software. Methods of communication from Reader-to-Hubinclude hardwire cable, Wi-Fi, Xbee/ZigBee, Bluetooth, and similar datastream connectivity methods. Hubs act as traffic controllers and thelink to the database and application software. They also have theresponsibility to issue scan commands to their respective array when acommand is triggered from the system. A full system could be comprisedof many readers and hubs all linked to a specific customer or site, oreven multiple customer sites. Hubs can be comprised of an array ofcommunication options, including Xbee/ZigBee, Wi-Fi, cellular modem,BLE, LoRa, LAN routers, etc. Hubs also comprise an SBC (Single BoardComputer) and an HMI (Human Machine Interface). The onboard computer andtouchscreen allow for setup and diagnostics of the system. It canmonitor reader and battery health, connectivity, and other relatedfunctions. FIG. 18 shows an exemplary schematic of a RFIDinterrogators/Hub system.

In FIG. 18, tags 94 (i.e., RFID tags) are shown in various zonesadjacent to readers 96 (i.e., RFID interrogators). RFID interrogators 12are connected to a power supply 95 for power, and they communicate backto a hub 97. The dashed lines indicate wired or wireless communicationfrom the reader 96 to the hub 97. In this example, a tag 94 is outside ascan zone 93 and thus would be “missing” from the system. This couldindicate misplaced, lost, destroyed, sold, or pilfered items. Tags 94 inoverlapping zones 93 have higher location resolution as well as productresolution as they will appear to be in multiple zones 93 at once.

Hubs 97 communicate to the database and server through various means.This could be a wired or Wi-Fi connection to a local network, cellularconnection to the cloud, or other means of system connectivity. Hubs 97are also registered within the software application with an identifierto assist in diagnostic and location functions.

One further aspect to the system, in one embodiment, is the server,database, and application software. The database can reside in the cloudor local to a user site, for example in cloud or network data storage98. User(s) can access the database through user interface software 99.In one embodiment, the database stores all relational data, historicaland current, including EPC's, names, timestamps, zone location, etc.(see also database embodiment in FIG. 17). FIG. 19 illustrates thestructure of one such database system, with the sub-systems shown. TheUI, where the end-user communicates and views the data can be through aweb browser, or mobile/desktop application. Variations and furtherdatabase systems may also be suitable.

FIG. 19 illustrates a schematic of a database system, called Vespy, thatforms a portion of the global inventory database subsystem 20. Thevarious components of the Vespy database system can be implemented insoftware (e.g., executing on a processing device), hardware, firmware,and various combinations thereof in various embodiments. In the Vespydatabase system, a user can access the database system through, forexample and without limitation, a web browser 108, the user interfaceVespy-UI 101, and the like. In one embodiment, Vespy-UI 101 is areactive single page application providing user interaction,configuration and display. Vespy-UI 101 permits tuning of reader overlap(Zones), scanning frequency, and display of up to the moment informationon status of inventory assets.

One aspect of the Vespy database system, Vespy-Central 102, providesinformation to the UI (e.g., for queries), and handles configurationcommands. Vespy-Central 102 transforms machine level data to providehuman intelligible information, through algorithms that process largenumbers of asset events from Vespy-IoT 103 to provide user tailoredlocation information at the area (Zone) or fine location (e.g., fromrssi and/or RFID sensing overlap of RFID readers/interrogators) level.Vespy-Central 102 processes configurations for volume and frequency ofmonitoring.

One aspect of the Vespy database system, Vespy-IoT 103, transforms bulkmachine data from devices in the field into informative events (e.g.,frex: tag changes zone). Vespy-Central 103 performs the filtering ofrepetitive scan information to reduce the usage of downstreamcomponents.

An additional aspect of the Vespy database system, VenaEventStore 104,stores a continuous stream of all events from update sources.VenaEventStore 104 allows the system to detect the status of a tag atany time point during system operation. VenaEventStore 104 allows thereview of the complete life cycle of the tag for the duration of thejourney of the tag in the system. Historical tracking of tag movementcan be replayed at any point in time for forensic purposes.VenaEventStore 104 permits the processing of large numbers of eventswithout collision.

One aspect of the Vespy database system, Azure Storage (Site Images) 105provides a storage solution for user site images.

One aspect of the Vespy database system, Active Directory 106, providesindustry standard identity management.

One aspect of the Vespy database system, IoT Event Hub 107, is a focalpoint for device events. The system is configured to leverage the AzureIoT Event Hub 107 to process incoming device messages at scale.

In the Vespy database system. The Web Browser 108 provides user accessto the database system. The user can access an application as a web app,in various embodiments.

One aspect of the Vespy database system, the IoT Hub 109, is the Azuredevice registration for communications.

FIG. 20 shows the SOP process flow within the application, includingevents, command issues, and queries. The various components illustratedin the process flow are implemented in software, hardware, firmware, andcombinations thereof in various embodiments. Commands and queries areissued by external services 122, which includes the Vena Chassis.Commands proceed through the command gateway 124, which may have aqueue, command sorter, command combiner or other command front endhandling, to the command dispatcher 132, which may have one or morecommand handlers (e.g., two command handlers shown). Queries proceedthrough the query gateway 126, which may have a queue, query sorter,query combiner or other query front end handling, to the query executor134, which may have one or more query handlers (e.g., two query handlersshown).

The event bus 130 passes domain events from the command dispatcher 132to appropriate components, for example RFID interrogators, and domainevents are also sent to the event store 128, for example, a database.Events are also passed through the event bus 130 and from the event bus130 to the event dispatcher 140, which has one or more event receivers(e.g., two event receivers shown), a synchronize entity and a projector.The synchronize entity sends apply to the entities 136, for example adatabase called Mongo (which may mean a large amount of memory). Theprojector sends project to projections 138, for example another databasealso called Mongo (e.g., a large amount of memory). Entities 136provides queries to the query executor 134.

The software application closes the loop and communicates to the userthe results of the scans, the current state and health of the system andassets, and historical data from the system as well. It can alsocommunicate back to ERP or POS (Point of Sale) systems. For example, ifitems were sold, and they were scanned leaving the front door, they canbe removed from the system. Pilfered, lost, or misplaced items can alsobe reported and then reconciled. If the user desires to locate aspecific asset within the site, this could be achieved with aspontaneous scan for a specific item by name or EPC. Historical data canalso be reported for tracking and analysis. For example, in amanufacturing facility, bottlenecks could be identified with historicaldata showing that an asset tagged as “Raw Material Cart A” was scannedentering the “Assembly Room” zone at a specific time and then wasscanned leaving at a subsequent time. With user levels and accesspermissions, different tasks and reports can be assigned to differentpersonnel within a facility. With the map generated in the beginning ofthe process, the software application can visually show assets, assetquantity, their respective location or travel history through the zones,time spent at a certain location, location and time last seen, etc. Theapplication software is intended to be customizable to account for thespecific customer needs.

FIG. 21 shows an exemplary schematic of a system architecture having twozones 70 called Zone “A” and Zone “B”, one hub 97 called Hub “A”, andfour assets 150 called Asset 1, Asset 2, Asset 3 and Asset 4. Reader 96called Reader “A” oversees zone 70 called Zone “A” and scans assets 150called Asset 1 and Asset 2. Reader 96 called Reader “B” oversees zone 70called Zone “B” and scans assets 150 called Asset 3 and Asset 4. Thereaders 96 communicate through hub 97 called Hub “A” with the server152, which communicates with the database 154 and the tag printer 156.Server 152 also executes ERP/POS software 158 and application software160, and generates custom reports 164 according to user permissions 162.

FIG. 22 shows one of many possible process flows of the FIG. 21 system(or variation thereof) based on the need for loss prevention of a highvalue asset. For system set up, there are the actions of zone creation174, e.g., identification of zones, placement of RFID readers orinterrogators and system parametric association of zones and possiblylocations within zones to the RFID interrogators, tag registration 176,asset(s) tagged 178, and asset(s) placed in zone 180. A zone scan 172 isinitiated by the scan trigger 170 responding to a timer, user trigger,motion sensor or other trigger, and may determine asset moved 182. Thezone scan 172 performs the action of send data to server 184.

In response to data being sent to the server in the action of send datato server 184, flow proceeds to a determination action 186. In adetermination action 186, the system determines is a tag showing in ascan. If the tag is not showing in a scan, the system generates an alert188 to alert the user of missing asset with timestamp. If the tag isshowing in a scan, flow proceeds to a determination action 190. In thedetermination action 190, the system determines if a tag is showing in a“correct” zone. If the tag is not showing in the correct zone, thesystem generates an alert 192, alert user of asset in a “wrong” ornon-anticipated zone. If the tag is showing in the correct zone, thesystem generates an alert 194 to alert the user of current location andtimestamp of the RFID identified tag/object.

RFID interrogators can include at least the following, as exemplarilyshown in one embodiment in FIG. 23. A microcontroller 200 configurableor otherwise capable of running firmware to handle local commands andGPIO. A Reader IC 208 that operates the RFID antenna 214, sending andreceiving RFID signals. An RFID antenna 214 that transmits and receivesthe RF energy to and from the RFID tag. Sensors and triggers, such as amotion sensor 212 and/or other triggers, that can give themicrocontroller 200 feedback in order to trigger a scan or report statesor conditions. Besides motion sensor(s) 212, other sensors 210 mightinclude temperature, humidity, door sensors, shock, inertia, vibration,and the like. Xbee 206, WIFI 204, and other wireless communication 202modules and methods. This could be one or more of many methods used intandem or as a redundancy program to send/receive data to the hub, andthe antenna 214 required for their respective communication protocol.

As one will appreciate, the system is able to be configured to handle awide range of tag density by user adjustment of the respectivefidelity/resolution levels of the system. In one aspect, higher fidelityto granularity of number of the RFID tags of items that can be detectedat a location can be determined through capability of detecting multipleRFID tags at a location, for example by a plurality of RFIDinterrogators 12 each capable of detecting multiple RFID tags. Toprovide an example of the bookends of such environments, one could havea warehouse shelf that is 5 ft.×5 ft.×10 ft. or 250 ft³. In onescenario, there might only be 1 tagged container in the shelf. In theother extreme, there might be 4 containers, each containing 100 taggedshirts. A variance from 1 tag per 250 ft³, all the way to 400 tags per250 ft³ is possible for such fidelity. In higher density tagenvironments, the system could optionally involve one or more RFIDinterrogators 12 penetrating the target space from different angles.This provides a higher degree of resolution and/or fidelity of thetarget space being scanned. This also helps with RF unfriendly assetssuch as liquids and metal objects. FIG. 24 shows one exemplary exampleof low vs. high fidelity system.

FIG. 24 depicts a low fidelity warehouse shelf 220 and a high fidelitywarehouse shelf 222, with arrangements of RFID interrogators 12appropriate to a targeted fidelity. The low fidelity warehouse shelf 220has two readers 96, called Reader A and Reader B, in an arrangementsuitable for detecting one tagged container 224. The high fidelitywarehouse shelf 222 as eight readers 96, called Reader A, Reader B,Reader C, Reader D, Reader E, Reader F, Reader G and Reader H, in anarrangement suitable for detecting four groups of 100 tagged assetseach, with appropriate fidelity and resolution.

In the case of resolution, the system can be user customized to providethe desired level of fidelity and/or resolution for respective tagsgeo-spatial location. In one aspect, lower resolution of the RFID tagsof items could be based on a single RFID interrogator detecting an RFIDtag at a location, and higher resolution of physical location of theRFID tags of items could be based on multiple RFID interrogatorsdetecting the same RFID tag at a time of determining physical locationof the tag, for example RFID interrogators with overlapping sensingareas. For example, the user might only require to know if a tag is onthe example 250 ft³ shelf. Thus the shelf, in the system software (e.g.,parametric association of zones, resolution and RFID interrogators) is asingle zone, with multiple RFID interrogators. The system only has toidentify that the tag is somewhere on the shelf. However, if the userneeds change, and they require much higher resolution, the system can bemodified (e.g., change parametric association of zones, resolution andRFID interrogators, and/or change the physical arrangement of readers)to meet those needs.

In one aspect and as described herein, system customization provides formultiple pathways for meeting the evolving user needs without thenecessity for adding additional RFID interrogators after an initialinstall within a warehouse space. With the system toolbox approach,there are many tools to employ to meet those needs. It is thecombination and coordination of these tools that allow the system toperform optimally.

It is contemplated that one such tool is RFID interrogator placement.RFID interrogators cab be placed logistically in the environment or sitein such a way as to not interfere with the user's normal functions andsuch that they will likely not get moved or damaged. The RFIDinterrogators can also be positioned in the warehouse space in such away that all the space that is intended to be covered, is covered, thusno dead spots.

Another such tool is scan management. Scan management refers to how andwhen the system triggers scans. This could be as simple as timers set upin the system software, or even user triggered scan. If a user needsspecific zones scanned more frequently than others, a user can set upthe system to implement various auto-scan routines. Optionally, if auser needs to identify when a particular RFID tagged asset is currentlylocated, the user can trigger a spontaneous scan. Optionally, it iscontemplated that other scan triggers could be sensor based. Forexample, if the identified need for a particular zone is lossprevention, the RFID interrogator could be triggered as a result of aninput received from an integrated motion sensor and a door trigger. Inthis exemplary aspect, any time someone is in the area or opens the doorthe system would trigger. Thus, for this solution, there would be noneed to have the scanner active all of the time as either or bothactions triggering a scan of the area any assets leaving a specific areawould be identified.

Zone definition can provide another user configurable aspect of thesystem. In operation, users have the ability customize the scan zone andRFID interrogator relationships within the software (e.g., system and/oruser-defined parameters) so as to represent a space as 1 or more zones,even though it may have fixed or varying number of RFID interrogator. Inthe described example above, the warehouse shelf is set up as 1 zone,but in fact it may have 8 readers all scanning from different anglesinto the desired identified space thereby effectively creating 8 readsub zones in this example, as shown in FIG. 25.

In this example warehouse shelf 230 in FIG. 25, eight readers 96 calledReader A, Reader B, Reader C, Reader D, Reader E, Reader F, Reader G andReader H scan into the shelf, but the user can then customize how thisperforms and reports within the system software. For example, this zonecould be named “Shelf 1”. All of the readers 96 report present tags asresiding in “Shelf 1”, so the system would report 400 individual assetsin “Shelf 1”. This is an example of higher fidelity, but lowerresolution. As the user resolution/fidelity needs change, and the needshifts to know, “Where are the individual tags located within Shelf 1?”In one aspect, the system can be configured to sub-divide the location“Shelf 1” into sub-locations. As one will appreciate, the system allowsfor the user defined creation of very complex sub-zones that allow thesystem to identify with a high degree of resolution.

Below in FIG. 26, a diagram of three readers 96 can be seen, as well asthe multitude of zones 232 that can be achieved. By looking at overlapof the respective zones, if a RFID tag shows up on 2 or more readers 96(RFID interrogators 12), the system can provide a high degree ofresolution or asset location. Zone definition is a practically endlesscombination of zone/sub-zone grouping and defining. By defining zones232 in the software with user-friendly names or locations, the systemhas the ability to report where a specific asset is within a very smallspace. Generally, there is a realistic limit to the capable spatialresolution of the system. As more readers can mean higher resolution, areasonable system that can pinpoint an asset to within a cubic footwould likely solve most user needs.

Another optional system process that is useful in monitoring/configuringdesired resolution is the use of RSSI (Received Signal StrengthIndicator). RSSI is a value placed on the returning signal from the tagsrepresenting the strength of the signal. In various embodiments, an RFIDinterrogator or processing device determines the RSSI while reading anRFID tag. The RSSI value can be used by the system to determine thedistance from the scanning antenna RFID interrogator to an RFID tag.There are many factors that can influence RSSI, but once the system issetup and has established a range of RSSI values, monitoring RSSI valuescan be a useful tool for approximate ranging in the system. In thisaspect, when an RFID tag is scanned and responds to the RFIDinterrogator, not only is the EPC code or ID sent to the server, but anRSSI and timestamp are attached to the data record.

Optionally, the system and process can configure RF blockers to create abarrier to RF scanning, thus giving the user the ability to define acustomizable, definitive end of one zone and/or the beginning ofanother. For examples, the RF blockers could be placed on a warehouseracking system or on a wall to prevent scanners from detecting tags inother areas not intended to be read.

In a further optional aspect, the system and process can configure scanpower and scan duration of the respective RFID interrogators 12. Thesystem and process can provide user customized adjustable settings fromwithin the software system that can assist in defining the fidelityand/or resolution of the system. It is contemplated that each individualRFID interrogator 12 has its own adjustable values. For example, andwithout limitation, the greater the output power, the longer the rangeand/or strength of the generated interrogation signal strength.Similarly, the longer the scan cycle generated interrogation signal, thegreater the chance of picking up all RFID tags within a define scanspace. It is further contemplated that the system and process canprovide for user electable time frames for the application or higherpower signal generation and interrogation, i.e., the application ofhigher power signal generation and interrogation can, for example, belimited to time frames and/or zones in which no personnel are currentlypresent.

In another optional aspect, the system and process can provide forsystem site mapping, which is a visual tool for a user to be ableunderstand various data outputs of the system in a graphical display. Itis contemplated that such a system site application in the softwaresystem would be customizable with respect to the floor plan, site, orarea that is in scannable space. For example, colors and graphicalelements can be used to display and report tag locations, quantities,travel history of asset(s), last seen locations, and the like.

As previously discussed, the RFID tags themselves can form anothercustomizable aspect of the system and process. Conventionally, RFID tagscan come in exceedingly small packages or large robust units. Some RFIDtags are active and can transmit long distances, as well as transmitsensor data such as temperature or humidity. Some RFID tags can beconfigured to be used with metal assets, and some are RFID tags areconfigured to be implanted. RFID tags variability gives more flexibilityto the system, and the ability meet and customize the system to fitspecific fidelity and/or resolution needs.

In a further additional optional aspect, the system and processcontemplates the use of at least one RFID interrogator having at leastone antenna, or a plurality of antennas, that is configurable formovement about an azimuth axis of the RFID interrogator. Optionally, itis also contemplated that a plurality of the RFID interrogators in asystem setup can each have at least one antenna, or a plurality ofantennas, that is configurable for movement about an azimuth axis of therespective RFID interrogator.

In this exemplary aspect, the use of movable antenna in the RFIDinterrogator(s) allow for an additional customizable increase/decreasein select system fidelity and/or resolution. Via the use of antenna thatcan move via motorized actuators, such as servo motors or steppermotors, antenna within the respective RFID interrogator can be pointedto specific and predetermined spaces along varied and selected signalgeneration azimuths. By knowing the parameters such as the azimuth,angle of rotation, etc., the system can effectively increase the numberof zones in a given defines space that are being interrogated (e.g.,each “azimuth zone” interrogated along a selected azimuth defines asingle zone in which multiple tags are potentially identified and, asthe incremental movement of the RFID interrogator antenna moves throughthe user selected azimuth angle range, it is contemplated that therespective azimuth zones, such as adjacent azimuth zones, will overlapto a degree, such degree being definable by the user). Thus, fidelityand/or resolution of the system can be further defined to desired levelsof granularity.

As described above, as an antenna of the RFID interrogator scans signalgeneration axis of the respective RFID interrogator moves relative tothe fixed space that is being interrogated. When a RFID tag appears, andthen disappears from the through the scan process, it can be assumedthat that particular RFID tag is within that angle of movement. In oneadditional optional aspect, by correlating to the RSSI data in memory,it can be assumed that when the RSSI is the strongest, the angle orazimuth of the antenna should be pointing directly at the RFID tag.

As previously noted, it is contemplated that similar results can beachieved by using multiple antennae in a single RFID interrogator. Inthis aspect, on setup, the system and process can record the azimuthdirection of each antenna in the single RFID interrogator. Themicrocontroller can then selectively switch between the internalantennae and, based on what antenna is “active” when a tag appears, cansignal to the system as to the respective azimuth of the RFID tag to therespective selected antenna of the RFID interrogator. If multiple RFIDinterrogators scan a RFID tag and each has a general azimuth, tagfidelity and/or resolution can be predicted and reported to the user.

A further feature to customized systems in some embodiments is antennatype and form factor. RFID interrogators and their respective antennacan be packaged in various forms for various environments orapplications. Antenna designs provide different dispersion cones,ranges, and penetration parameters. Some antennae are designed forlonger, narrower spreads, while others are the opposite. Antenna canalso have motorized poles or planes to give a user software-controlledmethods to vary an antenna design. In other words, by altering thestructure of the antenna, the tuning can be changed. This in turn canalter the range and dispersion cone of the scanned/read zone(s) of theparticular RFID interrogators used in the system.

As described in detail herein, the adaptive inventory management systemfor use in a materials handling facility can include a plurality ofreceptacles, a global inventory management system, and an RFIDinterrogator subsystem. In this aspect, the plurality of receptacles,such as the exemplified racks, can be configured to receive one or moreitems of a plurality of items, wherein each of the plurality of items isassociated with a Radio Frequency Identification (RFID) tag. In thisaspect, it is contemplated that each RFID tag stores a unique identifieras described herein.

Is this aspect, the global inventory database subsystem has a processingsystem having at least one memory of the processing system that isconfigured to store program instructions. The RFID interrogatorsubsystem includes a plurality of RFID interrogators and it iscontemplated that at least one of the RFID interrogators can be mountedin a fixed geospatial location in the materials handling facility.Further, each of the RFID interrogators can be configured to read theunique identifier of the RFID tag associated with each of the pluralityof items that are within a defined boundary of at least one scan zonegenerated by the respective RFID interrogator and to subsequentlycommunicate the unique identifier of the each scanned RFID tagidentified within each scan zone of the respective RFID interrogator tothe processing system.

Thus, in operation, the at least one memory of the processing system isconfigured to store program instructions that when executed cause thedefined boundaries each scan zone for each RFID interrogators to beselectively configured to effect user desired levels of fidelity and/orresolution with respect to the generated unique identifier of the eachscanned RFID tag within a defined space of the materials handlingfacility.

In optional aspects, the defined boundaries each of scan zone for eachRFID interrogators can be configured such that boundaries of therespective RFID interrogators do not overlap or, alternatively or incombination, the defined boundaries each of scan zone for each RFIDinterrogator is user configurable such that at least portions of thedefined boundaries of the respective RFID interrogators overlap with atleast adjacent or otherwise selected RFID interrogators to define atleast one overlapping scan zone. In this aspect, each overlapping scanzone and the associated RFID identifier data therefrom are created fromRFID identifier data received from each scan of the respective scanzones of the respective selected RFID interrogators, and the RFIDidentifier data of the each scanned RFID tag identified withinoverlapping scan zone is communicated to the processing system.

It is further contemplated that, in operation, the scan zones projectedby each RFID interrogators can be selectively configured to effect userdesired levels of fidelity and/or resolution via the use of one or moreconfigurable program options to include at least one of: changing thenumber of RFID interrogators to change the number of scan zonesprojected by the RFID interrogators within the defined space of thematerials handling facility; changing the use of overlapping scan zonesprojected by the RFID interrogators within the defined space of thematerials handling facility; changing the use of signal strength orphase shifting modalities within respective scan zones projected by theRFID interrogators within the defined space of the materials handlingfacility; changing the use of steerable antenna technologies in eachRFID interrogator to create multiple spaced scan zones generated fromeach of the RFID interrogators within the defined space of the materialshandling facility; or changing the use of steerable antenna technologiesin the RFID interrogators within the defined space of the materialshandling facility to create multiple overlapping scan zones from each ofthe RFID interrogators.

Thus, the user desired levels of fidelity and/or resolution can beselectively increased via the use of one or more configurable programoptions to include at least one of: increasing the number of RFIDinterrogators to increase the number of scan zones projected by the RFIDinterrogators within the defined space of the materials handlingfacility; increasing the use of overlapping scan zones projected by theRFID interrogators within the defined space of the materials handlingfacility; increasing the use of signal strength or phase shiftingmodalities within respective scan zones projected by the RFIDinterrogators within the defined space of the materials handlingfacility; increasing the use of steerable antenna technologies in eachRFID interrogator to increase the number of created multiple spaced scanzones generated from each of the RFID interrogators within the definedspace of the materials handling facility; or increasing the use ofsteerable antenna technologies in the RFID interrogators within thedefined space of the materials handling facility to increase the numberof created multiple overlapping scan zones from each of the RFIDinterrogators.

Further, it is contemplated that the user desired levels of fidelityand/or resolution can be selectively decreased via the use of one ormore configurable program options to include at least one of: decreasingthe number of RFID interrogators to decrease the number of scan zonesprojected by the RFID interrogators within the defined space of thematerials handling facility; decreasing the use of overlapping scanzones projected by the RFID interrogators within the defined space ofthe materials handling facility; decreasing the use of signal strengthor phase shifting modalities within respective scan zones projected bythe RFID interrogators within the defined space of the materialshandling facility; decreasing the use of steerable antenna technologiesin each RFID interrogator to decrease the number of created multiplespaced scan zones generated from each of the RFID interrogators withinthe defined space of the materials handling facility; or decreasing theuse of steerable antenna technologies in the RFID interrogators withinthe defined space of the materials handling facility to decrease thenumber of created multiple overlapping scan zones from each of the RFIDinterrogators.

Optionally, it is contemplated that the geospatial location of each ofthe plurality of receptacles can be stored within the at least onememory of the processing system. Optionally, the geospatial location ofthe at least one of the RFID interrogators mounted in a fixed geospatiallocation in the materials handling facility can be stored within atleast one memory of the processing system.

In a further aspect, at least one of the RFID interrogators can be amobile RFID interrogator configured to be operated by a mobile agent ofthe materials handling facility.

In a further aspect, each RFID interrogator can have an interface to theglobal inventory database subsystem, which interface can be configuredto be wired, wireless, or at least partially wireless.

In a further aspect, the RFID interrogator subsystem can furthercomprise at least one hub that is configured to act as a network node,which network node is configured to relay information to and from eachRFID interrogator to the global inventory database subsystem.

In a further aspect, the at least one of the RFID interrogators mountedin a fixed geospatial location in the materials handling facility cancomprises a plurality of fixed RFID interrogators mounted in a fixedgeospatial location in the materials handling facility, In this aspect,each of the plurality of fixed RFID interrogators are spaced from eachother and the geospatial location of the plurality of fixed RFIDinterrogators is stored within the at least one memory of the processingsystem. In this aspect, it is contemplated that the plurality of fixedRFID interrogators can include a direct wireless connection between therespective plurality of RFID interrogators for the sharing of certaindata.

In another aspect, each of the plurality of receptacles can associatedwith a RFID tag that stores a unique geospatial location identifier. Inthis aspect, it is contemplated that the geospatial location identifierof each of the plurality of receptacles is stored within at least onememory of the processing system, whereby a combination of the knownposition of the respective fixed plurality of RFID interrogators and theknown geospatial position of the respective receptacle mounted RFID tagsaid in increasing the fidelity of the geospatial location of inventoryitems within the materials handling facility.

In a further aspect, and as further described herein, the uniqueidentifier of the each scanned RFID tag comprises at least one of theunique identification code for each scanned item or the geospatiallocation identifier data associated with each scanned item to includethe date and time of a scanning event, whereby the warehouse inventorymanagement system can synchronize data associated with each inventoryitem received from different RFID interrogators.

As also described in further detail herein, the management system of canfurther comprise a motion detection subsystem that can be configured todetect movement within a defined region between a first physical zoneand a second physical zone. In this aspect, in response to detectingmovement, the processing system instructs the RFID interrogatorsubsystem to identify inventory items moving from the first physicalzone to the second physical zone and to subsequently report itemmovement to the global inventory database subsystem, the identity ofeach item identified as having moved allowing for the global inventorydatabase subsystem system to update the physical location of each itemthat transits from the first physical zone to the second physical zone.It is also contemplated that the global inventory database subsystem canbe configured to activate a scan, or to prevent a scan, depending on theneed and or event triggered by the motion detection subsystem.

In a further aspect, the global inventory database subsystem can beconfigured to activate a scan, or to prevent a scan, on a recurring orotherwise identified timeline or schedule.

As described in detail herein, the adaptive inventory management systemfor use in a materials handling facility can include a plurality ofitems positioned within a defined space of the materials handlingfacility, in which each of the plurality of items is associated with aRadio Frequency Identification (RFID) tag, wherein each RFID tag storesa unique identifier, a global inventory database subsystem and an RFIDinterrogator subsystem.

Is this aspect, the global inventory database subsystem has a processingsystem having at least one memory of the processing system that isconfigured to store program instructions. The RFID interrogatorsubsystem includes a plurality of RFID interrogators and it iscontemplated that at least one of the RFID interrogators can be mountedin a fixed geospatial location in the materials handling facility.Further, each of the RFID interrogators can be configured to read theunique identifier of the RFID tag associated with each of the pluralityof items that are within a defined boundary of at least one scan zonegenerated by the respective RFID interrogator and to subsequentlycommunicate the unique identifier of the each scanned RFID tagidentified within each scan zone of the respective RFID interrogator tothe processing system.

Thus, in operation, the at least one memory of the processing system isconfigured to store program instructions that when executed cause thedefined boundaries each scan zone for each RFID interrogators to beselectively configured to effect user desired levels of fidelity and/orresolution with respect to the generated unique identifier of the eachscanned RFID tag within a defined space of the materials handlingfacility.

In optional aspects, the defined boundaries each of scan zone for eachRFID interrogators can be configured such that boundaries of therespective RFID interrogators do not overlap or, alternatively or incombination, the defined boundaries each of scan zone for each RFIDinterrogator is user configurable such that at least portions of thedefined boundaries of the respective RFID interrogators overlap with atleast adjacent or otherwise selected RFID interrogators to define atleast one overlapping scan zone. In this aspect, each overlapping scanzone and the associated RFID identifier data therefrom are created fromRFID identifier data received from each scan of the respective scanzones of the respective selected RFID interrogators, and the RFIDidentifier data of the each scanned RFID tag identified withinoverlapping scan zone is communicated to the processing system.

It is further contemplated that, in operation, the scan zones projectedby each RFID interrogators can be selectively configured to effect userdesired levels of fidelity and/or resolution via the use of one or moreconfigurable program options to include at least one of: changing thenumber of RFID interrogators to change the number of scan zonesprojected by the RFID interrogators within the defined space of thematerials handling facility; changing the use of overlapping scan zonesprojected by the RFID interrogators within the defined space of thematerials handling facility; changing the use of signal strength orphase shifting modalities within respective scan zones projected by theRFID interrogators within the defined space of the materials handlingfacility; changing the use of steerable antenna technologies in eachRFID interrogator to create multiple spaced scan zones generated fromeach of the RFID interrogators within the defined space of the materialshandling facility; or changing the use of steerable antenna technologiesin the RFID interrogators within the defined space of the materialshandling facility to create multiple overlapping scan zones from each ofthe RFID interrogators.

In this aspect, and as further described herein, the unique identifierof the each scanned RFID tag comprises at least one of the uniqueidentification code for each scanned item or the geospatial locationidentifier data associated with each scanned item to include the dateand time of a scanning event, whereby the warehouse inventory managementsystem can synchronize data associated with each inventory item receivedfrom different RFID interrogators.

The foregoing has described various embodiments of warehouse inventorymanagement systems and methods of operation thereof; and, in particular,to systems utilizing RFID interrogators. The disclosed systems andmethods are provided to illustrate the essential and optional featuresand functions, and those skilled in the art may conceive of alternativesor modifications that do not depart from the principles of the inventionas encompassed by the appended claims, and that such alternatives ormodifications may be functionally equivalent.

What is claimed is:
 1. An adaptive inventory management system for usein a materials handling facility, comprising: a plurality of items,wherein each of the plurality of items is associated with a RadioFrequency Identification (RFID) tag, wherein each RFID tag stores aunique identifier; a global inventory database subsystem having aprocessing system, wherein an at least one memory of the processingsystem is configured to store program instructions; and an RFIDinterrogator subsystem comprising a plurality of RFID interrogatorsmounted in respective fixed geospatial locations in the materialshandling facility, wherein the plurality of fixed RFID interrogatorsincludes a direct wireless connection between respective RFIDinterrogators for the sharing of certain data, and wherein each of theRFID interrogators is configured to read the unique identifier of theRFID tag associated with each of the plurality of items that are withina defined boundary of at least one scan zone generated by the respectiveRFID interrogator, and to communicate the unique identifier of the eachscanned RFID tag identified within each scan zone of the respective RFIDinterrogator to the processing system; wherein the at least one memoryof the processing system is configured to store program instructionsthat when executed cause the defined boundaries each scan zone for eachRFID interrogators to be selectively configured to effect user desiredlevels of fidelity and/or resolution with respect to the generatedunique identifier of the each scanned RFID tag within a defined space ofthe materials handling facility.
 2. The adaptive inventory managementsystem of claim 1, wherein the defined boundaries each of scan zone foreach RFID interrogators is configured such that boundaries of therespective RFID interrogators do not overlap.
 3. The adaptive inventorymanagement system of claim 1, wherein the defined boundaries of eachscan zone for each RFID interrogator is user configurable such that atleast portions of the defined boundaries of the respective RFIDinterrogators overlap with at least adjacent or otherwise selected RFIDinterrogators to define at least one overlapping scan zone, wherein eachoverlapping scan zone and the associated RFID identifier data therefromare created from RFID identifier data received from each scan of therespective scan zones of the respective selected RFID interrogators, andwherein the RFID identifier data of the each scanned RFID tag identifiedwithin overlapping scan zone is communicated to the processing system.4. The adaptive inventory management system of claim 1, wherein the scanzones projected by each RFID interrogators are selectively configured toeffect user desired levels of fidelity and/or resolution via the use ofone or more configurable program options to include at least one of:changing the number of RFID interrogators to change the number of scanzones projected by the RFID interrogators within the defined space ofthe materials handling facility; changing the use of overlapping scanzones projected by the RFID interrogators within the defined space ofthe materials handling facility; changing the use of signal strength orphase shifting modalities within respective scan zones projected by theRFID interrogators within the defined space of the materials handlingfacility; changing the use of steerable antenna technologies in eachRFID interrogator to create multiple spaced scan zones generated fromeach of the RFID interrogators within the defined space of the materialshandling facility; or changing the use of steerable antenna technologiesin the RFID interrogators within the defined space of the materialshandling facility to create multiple overlapping scan zones from each ofthe RFID interrogators.
 5. The adaptive inventory management system ofclaim 4, wherein user desired levels of fidelity and/or resolution canbe selectively increased via the use of one or more configurable programoptions to include at least one of: increasing the number of RFIDinterrogators to increase the number of scan zones projected by the RFIDinterrogators within the defined space of the materials handlingfacility; increasing the use of overlapping scan zones projected by theRFID interrogators within the defined space of the materials handlingfacility; increasing the use of signal strength or phase shiftingmodalities within respective scan zones projected by the RFIDinterrogators within the defined space of the materials handlingfacility; increasing the use of steerable antenna technologies in eachRFID interrogator to increase the number of created multiple spaced scanzones generated from each of the RFID interrogators within the definedspace of the materials handling facility; or increasing the use ofsteerable antenna technologies in the RFID interrogators within thedefined space of the materials handling facility to increase the numberof created multiple overlapping scan zones from each of the RFIDinterrogators.
 6. The adaptive inventory management system of claim 4,wherein user desired levels of fidelity and/or resolution can beselectively decreased via the use of one or more configurable programoptions to include at least one of: decreasing the number of RFIDinterrogators to decrease the number of scan zones projected by the RFIDinterrogators within the defined space of the materials handlingfacility; decreasing the use of overlapping scan zones projected by theRFID interrogators within the defined space of the materials handlingfacility; decreasing the use of signal strength or phase shiftingmodalities within respective scan zones projected by the RFIDinterrogators within the defined space of the materials handlingfacility; decreasing the use of steerable antenna technologies in eachRFID interrogator to decrease the number of created multiple spaced scanzones generated from each of the RFID interrogators within the definedspace of the materials handling facility; or decreasing the use ofsteerable antenna technologies in the RFID interrogators within thedefined space of the materials handling facility to decrease the numberof created multiple overlapping scan zones from each of the RFIDinterrogators.
 7. The adaptive inventory management system of claim 1,further comprising a plurality of receptacles configured to receive oneor more items of the plurality of items, wherein the geospatial locationof each of the plurality of receptacles is stored within the at leastone memory of the processing system.
 8. The adaptive inventorymanagement system of claim 1, wherein the RFID interrogator subsystemfurther comprises at least one mobile RFID interrogator configured to beoperated by a mobile agent of the materials handling facility.
 9. Theadaptive inventory management system of claim 1, wherein each RFIDinterrogator has an interface to the global inventory databasesubsystem, which interface can be configured to be wired, wireless, orat least partially wireless.
 10. The adaptive inventory managementsystem of claim 1, wherein the RFID interrogator subsystem furthercomprises at least one hub that is configured to act as a network node,which network node is configured to relay information to and from eachRFID interrogator to the global inventory database subsystem.
 11. Theadaptive inventory management system of claim 1, wherein each of theplurality of fixed RFID interrogators are spaced from each other, andwherein the geospatial location of the plurality of fixed RFIDinterrogators is stored within the at least one memory of the processingsystem.
 12. The adaptive inventory management system of claim 1, furthercomprising a plurality of receptacles configured to receive one or moreitems of the plurality of items, wherein each of the plurality ofreceptacles is associated with a RFID tag, wherein each RFID tag foreach receptacle stores a unique geospatial location identifier; whereinthe geospatial location identifier of each of the plurality ofreceptacles is stored within at least one memory of the processingsystem, whereby a combination of the known position of the respectivefixed plurality of RFID interrogators and the known geospatial positionof the respective receptacle mounted RFID tags aid in increasing thefidelity of the geospatial location of inventory items within thematerials handling facility.
 13. The adaptive inventory managementsystem of claim 1, wherein the unique identifier of the each scannedRFID tag comprises at least one of the unique identification code foreach scanned item or the geospatial location identifier data associatedwith each scanned item to include the date and time of a scanning event,whereby the warehouse inventory management system can synchronize dataassociated with each inventory item received from different RFIDinterrogators.
 14. The adaptive inventory management system of claim 1,further comprising a motion detection subsystem configured to detectmovement within a defined region between a first physical zone and asecond physical zone, whereby, in response to detecting movement, theprocessing system instructs the RFID interrogator subsystem to identifyinventory items moving from the first physical zone to the secondphysical zone and to subsequently report to the global inventorydatabase subsystem, the identity of each item identified as having movedallowing the global inventory database subsystem system to update thephysical location of each item that transits from the first physicalzone to the second physical zone.
 15. The adaptive inventory managementsystem of claim 14, wherein the global inventory database subsystem isconfigured to activate a scan, or to prevent a scan, depending on theneed and or event triggered by the motion detection subsystem.
 16. Theadaptive inventory management system of claim 1, wherein the globalinventory database subsystem is configured to activate a scan, or toprevent a scan, on a recurring or otherwise identified timeline orschedule.
 17. An adaptive inventory management system, comprising: aplurality of items positioned within a defined space, wherein each ofthe plurality of items is associated with a Radio FrequencyIdentification (RFID) tag, wherein each RFID tag stores a uniqueidentifier; a global inventory database subsystem having a processingsystem, wherein an at least one memory of the processing system isconfigured to store program instructions; and an RFID interrogatorsubsystem comprising a plurality of RFID interrogators mounted inrespective fixed geospatial locations in the defined space, wherein theplurality of fixed RFID interrogators includes a direct wirelessconnection between respective RFID interrogators for the sharing ofcertain data, and wherein each of the RFID interrogators is configuredto read the unique identifier of the RFID tag associated with each ofthe plurality of items that are within a defined boundary of at leastone scan zone generated by the respective RFID interrogator, and tocommunicate the unique identifier of the each scanned RFID tagidentified within each scan zone of the respective RFID interrogator tothe processing system; wherein the at least one memory of the processingsystem is configured to store program instructions that when executedcause the defined boundaries each scan zone for each RFID interrogatorsto be selectively configured to effect user desired levels of fidelityand/or resolution with respect to the generated unique identifier of theeach scanned RFID tag within the defined space, and wherein the scanzones projected by each RFID interrogators are selectively configured toeffect user desired levels of fidelity and/or resolution.
 18. Theadaptive inventory management system of claim 17, wherein the RFIDinterrogator subsystem further comprises at least one mobile RFIDinterrogator configured to be operated by a mobile agent.
 19. Theadaptive inventory management system of claim 17, wherein each of theplurality of fixed RFID interrogators are spaced from each other, andwherein the geospatial location of the plurality of fixed RFIDinterrogators is stored within the at least one memory of the processingsystem.
 20. The adaptive inventory management system of claim 17,further comprising a motion detection subsystem configured to detectmovement within a defined region between a first physical zone and asecond physical zone, whereby, in response to detecting movement, theprocessing system instructs the RFID interrogator subsystem to identifyinventory items moving from the first physical zone to the secondphysical zone and to subsequently report to the global inventorydatabase subsystem, the identity of each item identified as having movedallowing the global inventory database subsystem system to update thephysical location of each item that transits from the first physicalzone to the second physical zone.
 21. The adaptive inventory managementsystem of claim 17, wherein the scan zones projected by each RFIDinterrogators are selectively configured to effect user desired levelsof fidelity and/or resolution via the use of one or more configurableprogram options to include changing the number of RFID interrogators tochange the number of scan zones projected by the RFID interrogatorswithin the defined space.
 22. The adaptive inventory management systemof claim 17, wherein the scan zones projected by each RFID interrogatorsare selectively configured to effect user desired levels of fidelityand/or resolution via the use of one or more configurable programoptions to include changing the use of overlapping scan zones projectedby the RFID interrogators within the defined space.
 23. The adaptiveinventory management system of claim 17, wherein the scan zonesprojected by each RFID interrogators are selectively configured toeffect user desired levels of fidelity and/or resolution via the use ofone or more configurable program options to include changing the use ofsignal strength or phase shifting modalities within respective scanzones projected by the RFID interrogators within the defined space. 24.The adaptive inventory management system of claim 17, wherein the scanzones projected by each RFID interrogators are selectively configured toeffect user desired levels of fidelity and/or resolution via the use ofone or more configurable program options to include changing the use ofsteerable antenna technologies in each RFID interrogator to createmultiple spaced scan zones generated from each of the RFID interrogatorswithin the defined space.
 25. The adaptive inventory management systemof claim 17, wherein the scan zones projected by each RFID interrogatorsare selectively configured to effect user desired levels of fidelityand/or resolution via the use of one or more configurable programoptions to include changing the use of steerable antenna technologies inthe RFID interrogators within the defined space to create multipleoverlapping scan zones from each of the RFID interrogators;
 26. Theadaptive inventory management system of claim 17, wherein the scan zonesprojected by each RFID interrogators are selectively configured toeffect user desired levels of fidelity and/or resolution via the use ofone or more configurable program options to include at least one of:changing the number of RFID interrogators to change the number of scanzones projected by the RFID interrogators within the defined space;changing the use of overlapping scan zones projected by the RFIDinterrogators within the defined space; changing the use of signalstrength or phase shifting modalities within respective scan zonesprojected by the RFID interrogators within the defined space; changingthe use of steerable antenna technologies in each RFID interrogator tocreate multiple spaced scan zones generated from each of the RFIDinterrogators within the defined space; or changing the use of steerableantenna technologies in the RFID interrogators within the defined spaceto create multiple overlapping scan zones from each of the RFIDinterrogators;
 27. The adaptive inventory management system of claim 17,wherein the unique identifier of the each scanned RFID tag comprises atleast one of the unique identification code for each scanned item or thegeospatial location identifier data associated with each scanned item toinclude the date and time of a scanning event, whereby the warehouseinventory management system can synchronize data associated with eachinventory item received from different RFID interrogators.
 28. Theadaptive inventory management system of claim 17, wherein the definedspace is in a materials handling facility.
 29. An adaptive inventorymanagement system for use in a materials handling facility, comprising:a plurality of items, wherein each of the plurality of items isassociated with a Radio Frequency Identification (RFID) tag, whereineach RFID tag stores a unique identifier; a global inventory databasesubsystem having a processing system, wherein an at least one memory ofthe processing system is configured to store program instructions; andan RFID interrogator subsystem comprising a plurality of RFIDinterrogators mounted in respective fixed geospatial locations in thematerials handling facility, wherein the plurality of fixed RFIDinterrogators includes a direct wireless connection between respectiveRFID interrogators for the sharing of certain data, wherein the RFIDinterrogator subsystem further comprises at least one mobile RFIDinterrogator; and wherein each of the RFID interrogators is configuredto read the unique identifier of the RFID tag associated with each ofthe plurality of items that are within a defined boundary of at leastone scan zone generated by the respective RFID interrogator, and tocommunicate the unique identifier of the each scanned RFID tagidentified within each scan zone of the respective RFID interrogator tothe processing system; wherein the at least one memory of the processingsystem is configured to store program instructions that when executedcause the defined boundaries each scan zone for each RFID interrogatorsto be selectively configured to effect user desired levels of fidelityand/or resolution with respect to the generated unique identifier of theeach scanned RFID tag within a defined space of the materials handlingfacility.
 30. The adaptive inventory management system of claim 29,wherein each of the plurality of fixed RFID interrogators are spacedfrom each other, and wherein the geospatial location of the plurality offixed RFID interrogators is stored within the at least one memory of theprocessing system.